Page 1 o.8 Safety first! Professional mechanics are trained in safe • • Always disconnect the battery earth terminal Always disconnect the battery ground (earth) working procedures. However enthusiastic you before working on any part of the fuel or electrical terminal before working on the fuel or electrical may be about getting on with the job at hand, system, and never risk spilling fuel on to a hot systems (except where noted).
Page 2: Identification Numbers
There should be a sticker on the bike's rear frame section (usually visible once the seat is lifted) which gives the model code number (eg 4TX4, meaning a 1999 TDM), the Yamaha production code number, and a letter indicating the colour code. The frame and engine numbers...
Page 3 ard for direct comparison. Whether buying new, used or rebuilt parts, the best course is to deal directly with someone who specialises in parts for your particular make. Started by Stalker UNREGISTERED VERSION OF PICTURE-DESK...
Page 4 • Check the oil level as shown in the appropriate Caution: Yamaha advise against using chemical oil additives, or oils with a grade of SH/CD photo sequence and top up if necessary. or higher, or oils labelled ENERGY CONSERVING II. Such additives or oils could cause •...
Page 5 Daily (pre-ride) checks o. TDM850 (1996-on) and TRX models Wipe the oil level window (arrowed) in the oil tank so that it is clean. With the motorcycle held vertical, the oil level should lie between the upper and lower level lines marked on the oil tank (arrowed).
Page 6: Before You Start
UNREGISTERED VI UNREGISTERED VI 0.12 Daily (pre-ride) checks 2 Brake fluid level checks Warning: Brake hydraulic fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouring it and cover surrounding surfaces with rag. Do not use fluid that has been standing open for some time, as it absorbs moisture from the air which can cause a dangerous loss of braking effectiveness.
Page 7 Daily (pre-ride) checks 0«13 Rear brake fluid level On TDM models, the rear brake fluid level is visible by looking up under On TRX models, the rear brake fluid level is visible through the the seat from the left-hand side of the rear wheel - it must be above reservoir body - it must be above LOWER level line (arrowed).
Page 8: Coolant Level Check
Yamaha dealer for a pressure test. 50% corrosion inhibited ethylene glycol anti- important that anti-freeze is used in the system freeze is needed. Note: Yamaha specify that soft all year round, and not just in the tap water can be used, but NOT hard On TDM models, the coolant reservoir FULL and LOW level lines are On TRX models, remove the seat (see Chapter 8).
Page 9 Many riders, however, consider a minimum of a tyre fitting specialist without delay. bar. of 2 mm tread depth to be a safer limit. Yamaha recommend a minimum of 1.5 mm on the front and 2 mm on the rear.
Page 10 1»1 Chapter 1 Routine maintenance and Servicing Contents Air filter - cleaning and renewal ............. Fuel hoses - renewal ................33 Battery - charging ..............see Chapter 9 Fuel filter - renewal (1999 TDM models) ..........23 Battery - check ..................11 Fuel system - check ................
Page 11: Routine Maintenance
1.2 Routine maintenance Specifications Engine Cylinder identification .................. No. 1 (left-hand), no. 2 (right-hand) Spark plugs Type ...................... NGK DPR8EA-9 or Nippondenso X24EPR-U9 Electrode gap ..................0.8 to 0.9 mm Engine idle speed TDM 1991 to 1995 models ..............
Page 12: Torque Settings
Throttle grip ....................Multi-purpose grease or dry film lubricant 'Yamaha advise against using chemical oil additives, or oils with a grade of SH/CD or higher, or oils labelled ENERGY CONSERVING II. Such additives or oils could cause clutch slip. TDM 1996-on models .................
Page 13 1.4 Component locations Rear brake fluid reservoir Oil level window (1996-on) Oil filler cap (1996-on) Front brake fluid reservoir Throttle cable upper adjuster Radiator pressure cap Coolant drain plug on water pump Clutch cable lower adjuster Oil filter and filter housing drain plug 10 Battery (1996-on) Steering head bearings...
Page 14 Component locations 1.5 Coolant reservoir Rear brake fluid reservoir Oil level window Oil filler cap Front brake fluid reservoir Throttle cable upper adjuster Radiator pressure cap Coolant drain plug on water pump Clutch cable lower adjuster 10 Oil filter and filter housing drain plug Clutch cable upper adjuster Steering head bearing...
Page 15: Component Locations
.6 Component locations Rear brake fluid reservoir Oil filler cap/dipstick Throttle cable upper adjuster Front brake fluid reservoir Steering head bearing adjuster Coolant drain plug on water pump Clutch cable lower adjuster Oil filter and filter housing drain plug Radiator pressure cap Clutch cable upper adjuster Air filter Battery...
Page 16 After the initial 600 miles (1000 km) months (whichever comes sooner) Note: This check is usually performed by a Yamaha dealer after the Carry out all the items under the 4000 mile (6000 km) check, plus the first 600 miles (1000 km) from new. Thereafter, maintenance is following: carried out according to the following intervals of the schedule.
Page 17 1.8 Introduction never performed any maintenance on it, then you 1 This Chapter is designed to help the home repair, machine should cleaned may want to start at the nearest interval and mechanic maintain his/her motorcycle for safety, thoroughly, especially around the oil filter, spark economy, long life and peak performance.
Page 18 Chapter, then (kerosene), then wipe it off and allow it to dry, side plates better than when cold. Note: Yamaha tighten the adjuster locknuts securely (see using compressed air if available. If the chain is specifies SAE 30 to 50W engine oil;...
Page 19 Yamaha 2 On XTZ models, remove the fuel tank and the |Tflfl|33 -As the plugs are quite do not specify a renewal interval, but leave it to air filter housing (see Chapter 4).
Page 20: Idle Speed
Every 4000 miles (6000 km) or 6 months 1.1.1 gauge take-off points on the intake manifolds. Do not allow exhaust gases to build up in the work area; either perform the check outside or use an exhaust gas extraction system. 1 Carburettor synchronisation is simply the process of adjusting the carburettors so they pass the same amount of fuel/air mixture to each...
Page 21 1.12 Every 4000 miles (6000 km) or 6 months 4.7b ... and remove the blanking plug (arrowed) 4.7a On XTZ models, detach the vacuum hose (arrowed). the linkage, and recheck the gauge readings, models, connect the gauge hoses to the takeoff readjusting if necessary.
Page 22 Every 4000 miles (6000 km) or 6 months 1*13 5.3b ... and remove the cover and element 5.4 Clean the element using compressed air 5.6 Make sure the element is correctly together if available seated Check 4 Tap the element on a hard surface to dislodge fuel tank and the fuel tap(s) (see Chapter 4).
Page 23 On 1996-on TDM use different indicators to those on the original metal in the oil, then something is and TRX models, Yamaha specify using new ones as equipment as shown. drastically wrong internally and the a matter of course.
Page 24 Every 4000 miles (6000 km) or 6 months 9.5a Rear brake light switch ■ 9.3 Flex the brake hoses and check for 9.5b Rear brake light switch - TRX models cracks, bulges and leaking fluid models 2 Check the brake lever and pedal for loose connections, improper or rough action, excessive play, bends, and other damage.
Page 25 On TRX models, first remove the adjuster cover (see iliustration). To 8 Check the position of the brake pedal. Yamaha reduce freeplay, slacken the rear nut and tighten recommend the distance between the top of the...
Page 26 UNREGISTERED VI UNREGISTERED VI Every 4000 miles (6000 km) or 6 months 1.17 13.2 Checking for play in the wheel bearings 11.2 Check that the electrolyte level is between the UPPER and LOWER level lines (arrowed) Spoked wheels 2 XTZ models are fitted with a standard 14 Sidestand and cut-off battery which requires regular checks of the 2 On XTZ models, visually check the spokes for...
Page 27: Throttle Cables
If leaks are noted, cap's condition, have it tested by a Yamaha Rear axle nut remove the radiator (see Chapter 3) and have it dealer or renew it. Install the cap by turning it Brake caliper mounting bolts repaired or renew it.
Page 28: Choke Cable
Every 4000 miles (6000 km) or 6 months 1.19 Freeplay adjustments can be made at the upper end of the accelerator cable. Loosen the locknut on the adjuster (see illustration). Turn the adjuster until the specified amount of freeplay is obtained, then retighten the locknut.
Page 29: Front Suspension
4 Next, grasp the fork sliders and try to pull and 5 Inspect the rear shock for fluid leakage and to-side). Yamaha specify a maximum lateral push them forward and backward. Any looseness tightness of its mountings. If leakage is found,...
Page 30 Check that the steering is still able to move freely from side to side, but that all freeplay is eliminated. 10 If the Yamaha tool is not available, using either a C-spanner, a peg spanner or a drift located in one of the notches, slacken the...
Page 31 18 If the Yamaha tool is not available, using either a C-spanner or drift located in one of the notches, slacken the adjuster nut slightly until (arrowed) 21.16 Slacken the fork clamp bolts (A) and...
Page 32 Every 8000 miles (12,000 km) or 12 months 1.23 22.6a Unscrew the filter cover bolts 22.6b ... and remove the cover and filter 22.7a Fit the new O-rings (arrowed)... (arrowed)... level up to the maximum level line on the dipstick or window.
Page 33 1.24 Every 16,000 miles (24,000 km) or 2 years 27.2a Unscrew the water pump drain plug (arrowed)... 27.2b ... and allow the coolant to drain brake bleeding section in Chapter 7, noting that painted surfaces of the motorcycle. Rinse off 2 Position a suitable container beneath the all old fluid must be pumped from the fluid spills immediately with plenty of water.
Page 34 Every 16,000 miles (24,000 km) or 2 years 1.25 7 Fill the cooling system with clean water mixed with a flushing compound. Make sure the flushing compound compatible with aluminium components, and follow the manufacturer's instructions carefully. 8 Start the engine and allow it to reach normal operating temperature.
Page 35 UNREGISTERED VERSION OF PI .26 Every 28,000 miles (42,000 km) 28.5b Note the position of the cam lobes (arrowed) With the cylinder at TDC on the compression stroke the lobes should 28.6 Make sure the cam lobes (arrowed) face away from each not be depressing the valves and should be facing away from each other, then check the valve clearances as shown other...
Page 36 I UNREGISTERED VI Every 28,000 miles (42,000 km) 1.27 INSTALLED SHIM SIZE MEASURED CLEARANCE 140 1145 230:235 0.00-0.04 125 130 2151220 0.05-0.09 130 135 220 1225 0.10-0.14 135 140 2251230 0.15-0.20 RECOMMENDED CLEARANCE 0.21-0.25 0.26-0.30 0.31-0.35 0.36-0.40 0.41-0.45 0.46-0.50 0.51-0.55 0.56-0.60 0.61-0.65 0.66-0.70...
Page 37 1.28 Every 28,000 miles (42,000 km) 13 Obtain the replacement shim, then lubricate it with molybdenum disulphide oil (a 50/50 mixture of molybdenum disulphide grease and engine oil) and fit it into its recess in the top of the valve, with the size marking on each shim facing up (see illustration 28.10c).
Page 38 Non-scheduled maintenance 1.29 bearing oil clearances are excessive and the 2 The only tools required are a compression engine needs to be overhauled. gauge and a spark plug wrench. A compression 6 If the oil appears very quickly and spurts out, gauge with a threaded end for the spark plug 12 the pressure may be too high, meaning either an mm diameter hole is preferable to the type which...
Page 39 i.3o Non-scheduled maintenance 1989 to 1994 XTZ models Specifications) and pump the fork at least ten 34 Front forks - oil change times to distribute it evenly; the oil level should 4 Fork oil degrades over a period of time and also be measured and adjustment made by loses its damping qualities.
Page 40 Chapter 2 Engine, clutch and transmission Contents Alternator rotor and stator - removal and installation .. .see Chapter 9 Major engine repair - general note ............4 Balancer shafts - removal, inspection and installation ......23 Neutral switch - check, removal and installation ....see Chapter 9 Cam chain and guides - removal, inspection and installation ....24 Oil and filter - change ............see Chapter 1 Cam chain tensioner- removal, inspection and installation .......
Page 41: Cylinder Head
UNREGISTERED VERSION OF PICTURE-DESK | 2»2 Engine, clutch and transmission Camshafts Inlet lobe height 1991 to 1995 TDM models and XTZ models Standard ....................35.7 to 35.8 mm Service limit (min) ................. 35.6 mm 1996-on TDM models and TRX models Standard ....................
Page 42 Engine, clutch and transmission 2*3 Pistons Piston diameter (measured 4.5 mm (TDM and TRX models) or 4.7 mm (XTZ models) up from skirt, at 90° to piston pin axis) TDM and TRX models ................89.420 to 89.435 mm XTZ models ....................86.920 to 86.935 mm Standard Service Limit...
Page 43: Oil Pump
2»4 Engine, clutch and transmission Clutch Friction plate thickness - all models Standard ....................2.9 to 3.1 mm Service limit (min) ..................2.8 mm Plain plates 1991 to 1995 TDM models and all XTZ models Thickness (special 'slick' plate) .............. 2.2 to 2.4 mm Thickness (all other plates) ..............
Page 44 Engine, clutch and transmission 2*5 1999 TDM models ;67/39T) Primary reduction ................. 1.718 to 1 ;43/16T) Final reduction ..................2.688 to 1 '37/14T) 1st gear ....................2.643 to 1 2nd gear ....................1.947 to 1 '37/19T) 3rd gear ....................1.500 to 1 30/20T) 27/23T) 4th gear ....................
Page 45: General Information
2*6 Engine, clutch and transmission Torque settings (continued) Outer sprocket cover bolts ................5 Nm Oil pump mounting screws ................6 Nm Oil pump assembly screw ................6 Nm Oil pump cover bolts ................... 10Nm Oil pipe to oil pump cover bolts ..............10 Nm Oil pipe banjo bolts to crankcase cover/oil tank and cylinder head ..
Page 46 Engine, clutch and transmission 2»7 it to avoid the possibility of damaging it while Conversely, a neglected engine, or one which general rule, time is the primary cost of an removing the engine. has not been run in properly, may require an overhaul so it does not pay to Install worn or 4 Remove the fuel tank (see Chapter 4).
Page 47 2»8 Engine, clutch and transmission 5.14 Unscrew the nut and detach the starter motor lead from the 5.16 Unscrew the bolt (arrowed) and detach the cable and hose clip starter relay 14 Disconnect the starter motor lead from the (see illustration). Discard the O-ring as anew 17 Detach the clutch cable from the release starter relay (see illustration).
Page 48 Engine, clutch and transmission 2*9 5.21b ... and right-hand engine brackets 5.21c Upper rear engine mounting bolt 5.21d Lower rear engine mounting bolt (arrowed) (arrowed) 5.21f ... and the bottom bracket (arrowed) 5.22a Engine bracket bolts (A) and upper 5.21 e Remove the triangular bracket front mounting bolt (B) - right-hand side (arrowed)...
Page 49 U.Hi.lS.iHiD.iHSin.nFPICUHi-DiSK 2»10 Engine, clutch and transmission frame bolts (left-hand side), and finally the engine bracket-to-engine and frame bolts (right-hand side), tightening them all to their specified torque. Fit the caps into the upper front bolts. e) On XTZ models, locate the swingarm pivot bolt first, followed by the lower and upper and rear mounting bolts, then fit the frame downtubes, and finally locate the lower front...
Page 50 r UNREGISTERED VERSION OF PICTURE-DESK Engine, clutch and transmission 2*11 3 Before commencing work, read through the appropriate section so that some idea of the necessary procedure can be gained. When removing components it should be noted that great force is seldom required, unless specified. In many cases, a component's reluctance to be removed is indicative of an incorrect approach or removal method - if in any doubt, re-check with...
Page 51 2*12 Engine, clutch and transmission 7.10a Install the valve cover... 7.10b ... and tighten the bolts 8.2a Unscrew the timing inspection plug (A) and the 8.2b Turn the engine using a socket on the alternator bolt centre plug (B) 10 Position the valve cover on the cylinder Discard the plug O-rings as new ones should be compression stroke.
Page 52 Engine, clutch and transmission 2*13 8.3b Note the alignment of the timing mark letters on the 8.3c ... and of the punch marks (A) on the ends of the camshafts with the lines (B) on the camshaft holders sprockets with the cylinder head... holders are marked with a letter and number to surface and faces back, while the 'I' mark on the inserting a screwdriver or bar through the hole in...
Page 53 UNREGISTERED VI 2*14 Engine, clutch and transmission 8.9 Unscrew and remove the camshaft holder bolts (arrowed) 8.10a Lift out the follower ... 8.10b ... and remove the shim either from inside the follower... 8.10c ... or from the top of the valve locations are readily identifiable by the differing pattern, until they are all loose (see...
Page 54 Engine, clutch and transmission 2*15 nft i ■ A 8.12b Measure the height of the camshaft 8.13 Measuring camshaft runout 8.15 Lay a strip of Plastigauge across lobes with a micrometer each bearing journal, parallel with the camshaft centreline with micrometer (see illustration)
Page 55 2*16 Engine, clutch and transmission 8.22 Fit the followers onto the valves 8.25 Install the camshafts as shown, with the No. 1 cylinder lobes (A) facing away from each other and the punch mark (B) on each sprocket holder facing up 20 Inspect the cam chain guide blade (see their original...
Page 56 Engine, clutch and transmission 2*17 8.28a Fit the exhaust sprocket into the 8.28b ... then fit the inlet sprocket 8.29a Install the sprocket bolts and counter-hold the camshafts as shown... chain and onto the camshaft... 8.33 Use new O-rings on the plugs 8.29b ...
Page 57 2*18 Engine, clutch and transmission 9.5 Release the ratchet and press the 9.8a Install the tensioner using a new 9.8b ... and tighten the mounting bolts to the plunger In gasket... specified torque specified at the beginning of the Chapter (see Note 2: If no work is being carried out on the illustrations).
Page 58 Engine, clutch and transmission 2»19 10.6b On TRX models, remove the blanking cap, then remove the frame- 10.7 Cylinder head bolts (A) and nuts (B) to-cylinder head bolt (arrowed) on each side Installation 6 On TDM and TRX models, unscrew the engine them finger-tight (see illustration).
Page 59 2»20 Engine, clutch and transmission 10.18a Use new sealing washers on each 10.18b ... and tighten the banjo bolt to the side of the union ... specified torque the union, and tighten the banjo bolt to the Use compressed air, if available, to blow out all specified torque (see illustrations).
Page 60 Engine, clutch and transmission 2«21 12.13 Measure the valve seat width with a 12.14b Insert a small-hole gauge into the 12.14a Measure the valve stem diameter ruler {or for greater precision use a vernier with a micrometer valve guide and expand it so there's a caliper) slight drag when it's pulled out 6 Repeat the procedure for the remaining...
Page 61 2»22 Engine, clutch and transmission A Head diameter B Face width C Seat width D Margin thickness U --- "A"—*J 12.16 Valve head measurement points Reassembly your hands. Use a back-and-forth motion (as illustration). If it is thinner than specified, renew though rubbing your hands together) rather than the valve.
Page 62 Engine, clutch and transmission 2»23 Jr **-*" / .,■ ■>: ' tJ/^k ^•gC^vT ^A ®J /^MsR^ .*>jOm^' ^3^r~~ ... .-- >^B| 12.25a Fit the spring seat... 12.25b ... then press the valve stem seal into position using a suitable deep socket 14.26c ...
Page 63 3 Hold the cam chain up and lift the cylinder and honed by a Yamaha dealer or engineer. If compress the stones and withdraw the hone. block up, then pass the cam chain down through...
Page 64 I UNREGISTERED VI Engine, clutch and transmission 2»25 13.15 Lay the new gasket over the dowels (arrowed) and onto the 13.17 Carefully lower the block onto the pistons crankcase 13.20a Fit a new O-ring onto the union . 13.20c 13.20b ... and the joint pipe . .
Page 65 2«26 Engine, clutch and transmission 14.3a Prise out the circlip ... 14.3b ... then push out the pin and 14.5 Removing the piston rings using < remove the piston ring removal and installation tool flat-bladed screwdriver inserted into the notch the deposits have been scraped away.
Page 66 UNREGISTERED VERSION OF PICTURE-DESK line, clutch and transmission 2*27 14.16a Align the piston with the 14.13a Slip the pin (A) into the piston (B) 14.13b Measuring the internal diameter of connecting rod small-end and insert the and try to rock it back and forth. If it's the bore in the piston loose, renew the piston and pin 13 Apply clean engine oil to the piston pin,...
Page 67 UNREGISTERED VI 2*28 Engine, clutch and transmission • ^a&jiffj ■ •" "J™ Hc~ s 15.11 Compression ring top surface is marked by a letter 25° \ 15.9b ... and fit the side rails each side of it. 15.9a Install the oil ring expander in its ^7®...
Page 68 Measure the thickness of each rear tyre in firm contact with the ground. friction plate using a vernier caliper (see Alternatively, the Yamaha service tool (pt. no. illustration). If any plate has worn to or 90890-04086), or a similar homemade tool made...
Page 69 2*30 Engine, clutch and transmission Specifications at the beginning of the Chapter, the friction plates must be renewed as a set. Also, if any of the plates smell burnt or are glazed, they must be renewed as a set. 14 The plain plates should not show any signs of excess heating (bluing).
Page 70 Engine, clutch and transmission 2»31 Clutch plate pack guide Model No. of plates Order of fitting to clutch centre 1991-93 TDM 8 friction, 8 plain start with the special 'slick' plain plate, then alternate friction and plain plates until ending with special friction plate which has a slot in one of its tabs.
Page 71 UNREGISTERED VI 2«32 Engine, clutch and transmission 16.26a ... then slide the clutch centre 16.26b Install the lockwasher, fitting the 16.25 Fit the outer thrust plate . onto the splines smaller bent tabs into the slots in the centre 16.26d ... and tighten it to the specified torque, 16.26c Fit the nut.
Page 72 Engine, clutch and transmission 2*33 16.29 Fit the pullrod assembly in the back of the pressure plate 16.30a Install the pressure plate, aligning the punch marks (arrowed)... 29 Lubricate the thrust bearing and washer with molybdenum disulphide oil (a 50/50 mixture of molybdenum disulphide grease and engine oil).
Page 73: Clutch Cable
2*34 Engine, clutch and transmission 17.1a Unscrew the two bolts (arrowed) and 17.1b Unscrew the two bolts (A) securing 17.1c Bend back the retaining tab .. displace the tap the cable bracket, noting the idle speed adjuster (B) fits (see illustrations). with that in the lever bracket, then pull the outer 17 Clutch cable- &...
Page 74 UNREGISTERED VERSION OF PICTURE-DESK line, clutch and transmission 2»35 17.5 Bend the tab to secure the cable in 18.2 The gear should rotate freely in the 18.4 Check the surface of the hub (A) and the lever the sprags (B) as described direction shown 5 Installation is the reverse of removal.
Page 75 2»36 Engine, clutch and transmission 19.5 Draw the gearchange shaft and selector arm assembly off the Note how the roller locates in the neutral detent (arrow), selector drum and out of the casing then unscrew the bolt and remove the stopper arm 19.6b If required, unscrew the bolts (A) and remove the plate and the 19.8 Gearchange shaft centralising spring can be removed after spring (B)
Page 76 Engine, clutch and transmission 2*37 19.10b ... then fit the retainer plate 19.10a Locate the stopper arm spring ... 19.9c ... and press or drive a new one in -■ w _______ f __________ l ____________ 19.11a Apply thread lock to the bolt... 19.12 The installed assembly should be as 19.11 b ...
Page 77 2*38 Engine, clutch and transmission 20.5a Remove the circlip. 20.5b ... and slide off the gear 20.6 Feed pump screws (A), scavenge pump screws (B) 20.7a Remove the screw (arrowed). 20.7b ... and separate the housing 20.7c Draw out the shaft and remove the rotors Discard the gasket as a new one must be used.
Page 78 Engine, clutch and transmission 2«39 20.11 Measuring outer rotor-to-body 20.10b Measuring inner rotor tip-to-outer 20.10a Assembled oil pump clearance rotor tip clearance the pump body and, using a feeler gauge, the feed pump (see illustration 20.7b and a). in the slots in the rotor, then fit the inner rotor into 15 Rotate the pump shaft by hand and check measure the rotor end-float (the gap between the the outer rotor (see illustration).
Page 79 2*40 Engine, clutch and transmission 20.19b ... then install the cover 20.18 Fit a new O-ring around the collar 20.19a Make sure the gasket fits onto the dowels (arrowed)... into the orifice in the scavenge pump, then fit a new O-ring (see illustration). 19 If removed, fit the oil pump cover dowels into the crankcase, then install the cover using a new gasket, making sure it locates correctly onto the...
Page 80 UNREGISTERED VI Engine, clutch and transmission 2*41 22.4a Remove the screws (arrowed). 22.3 Unscrew the bolts (arrowed) and remove the sump illustration). Discard the gasket as a new one positions of the two dowels and remove them d) Tighten the oil tank base and top bolts to must be used.
Page 81 UNREGISTERED VI 2*42 Engine, clutch and transmission engine bashplate (see Chapter 8). Start the engine and check that there are no oil leaks around the sump and oil filter cover. 23 Balancer shafts - removal, inspection and installation Note: On 1991 to 1995 TDM models and XTZ models, the balancer shafts can be removed with the engine in the frame.
Page 82 If they are worn, the weight must be renewed as the bearings are not listed as being available separately, though it is worth checking with a Yamaha dealer or bearing specialist. remove the holder... 23.11 Align the Woodruff key slot (A) with 23.12a Align the punch mark on the gear...
Page 83 2*44 Engine, clutch and transmission '■ft Ts* 23.13a Fit a new O-ring into the narrow 23.13b Align the punch mark on the gear (A) 23.13c Fit the holder onto the dowels groove with the mark on the crankcase (B) (see illustration). Apply clean engine oil to the counter-sink for the screw heads on the outside, gasket, then tighten the bolts evenly in a criss- shaft.
Page 84 Engine, clutch and transmission 2*45 24.4b ... and lift it out 24.2 Draw the cam chain out of the engine 24.4a Note how the front guide locates in the cylinder head (arrow)... cover (see Section 20). Unscrew the bolt (see 24 Cam chain and guides - 25 Crankcase halves - illustration).
Page 85 2*46 Engine, clutch and transmission 3 Unscrew the bolts securing the transmission 5 Turn the engine upside down so that it rests on output shaft retainer plate to the left-hand side of the cylinder head studs. the crankcase and remove the plate (see 6 Unscrew the 6 mm lower crankcase bolts, the illustration).
Page 86 14 Apply a small amount of suitable sealant ruined. if it is loose (it could be in either crankcase half) (such as Yamaha Bond 1215) to the outer mating 17 Clean the threads of the 10 mm lower crankcase bolts...
Page 87 2»48 Engine, clutch and transmission removed from the mating surfaces. Minor 4 Dirt and other foreign particles get into the damage to the surfaces can be cleaned up with a engine in a variety of ways. It may be left in the fine sharpening stone or grindstone.
Page 88 8 Have the rods checked for twist and bend rods. Immediately install the relevant bearing the crankcases separated. by a Yamaha dealer or engineer if you are in shells (if removed), bearing cap, and nuts on each piston/connecting rod assembly so that doubt about their straightness.
Page 89 UNREGISTERED VI UNREGISTERED VERSION OF PICTURE-DESK | 2*50 Engine, clutch and transmission 28.21a Big-end journal size numbers (A), 28.21b Connecting rod size number is 28.22 Bearing shell colour code location main journal size numbers (B) marked across the cap and rod join the bolt shanks and threads and to the seats Bearing shell selection fitted the correct way around so the...
Page 90 Engine, clutch and transmission 2»51 29.3 Carefully lift the crankshaft out of the 29.4 To remove a main bearing shell, push it 29.5 Check the condition of the gear and crankcase sideways and lift it out sprocket teeth crankcase half, taking care not to dislodge the bearing oil clearance is measured with a product Place a strand of Plastigauge on each (cleaned) main bearing shells (see illustration).
Page 91 2»52 Engine, clutch and transmission crankcase halves. This will ensure all bolts are right-hand end (see illustration 28.21a). The installed in the correct location on reassembly. block of three numbers are for the main bearing 18 Turn the engine upside down so that it rests journals (the block of two numbers are for the on the cylinder head studs.
Page 92 Engine, clutch and transmission 2«53 30.4a Draw out the shaft once the retainer screws have been 30.2 Lift out the output shaft removed rod as a guide to align the holes, as once the 6 Referring Tools Workshop Tips upper crankcase, making sure all bearings retainer is in the housing it will be difficult to turn.
Page 93 UNREGISTERED VI 2*54 Engine, clutch and transmission 30.7d Fit a new O-ring onto the plug . 30.7e ... and press it into place 30.9 Fit the half-ring retainer into the slot 8 Install the selector forks (see Section 32). that to draw the bush off (see illustration). 31 Transmission shafts- 9 Install the bearing half-ring retainer for the Remove the thrust washer and the 3rd gear...
Page 94 Engine, clutch and transmission 2»55~ 31.15b 31.15c ... and secure them with the circlip 31.15a Slide the 4th gear pinion onto the . then slide on the splined washer..bush... correctly in the groove in the shaft (see mating surfaces of the shaft, pinions and bushes. illustrations).
Page 95 31.18b ... and set the distance as specified 31.19 The assembled input shaft should be as shown the 1st gear pinion (which is integral with the individually - refer to a Yamaha dealer if they 33 Slide the 4th gear pinion onto the shaft, with shaft) is 116.6...
Page 96 ■ Engine, clutch and transmission 2*57 ■ PPPP^^^^M ■f!*f. . • jr . ■ 31,39a Slide on the splined bush .. 31.38b ... and align it as shown ... 31.38c ... then slide the lockwasher on, fitting the tabs into the slots shaft, so that the tabs on the lockwasher face the left-hand end of the shaft and locate into the slots in the outer rim of the splined washer (see...
Page 97 2*58 Engine, clutch and transmission 32.4 Note the letter on each fork denoting its position 32.12 Slide the drum into the casing Inspection 2 Remove the transmission output shaft (see if necessary (see Tools and Workshop Tips Section 30, Step 2). (Section 5) in the Reference Section).
Page 98 3 As there isn't an oil pressure warning light which Yamaha provide for new motorcycles, fitted, an oil pressure check must be carried can be used as a guide.
Page 99 UNREGISTERED VI UNREGISTERED VI Chapter 3 Cooling system Contents Coolant hoses - removal and installation ..........9 General information ................. Coolant level check ........... see Daily (pre-ride) checks Radiator - removal and installation ............Coolant reservoir - removal and installation ..........3 Radiator pressure cap - check ..............
Page 100 Chapter 1. The radiator cap opening the engine is hot. Scalding hot coolant thermostat and through to the radiator. The pressure should be checked by a Yamaha dealer and steam may be blown out coolant then flows across the radiator core, with the special tester required to do the job.
Page 101: Cooling Fan
Cooling system 3*3 4.3a Fan motor wiring connector (arrowed) - TDM models 4.3b Fan motor wiring connector (arrowed) - XTZ models does not, and the wiring is all good, then the 2 If the fan does not come on, (and the fan 4 Cooling fan and cooling fan §| fan is faulty.
Page 102: Coolant Temperature Warning Light
3*4 Cooling system cutting in at the wrong temperature, a more connector(s) from the fan switch, mounted in the 3 If the needle movement is still faulty, or if it comprehensive test of the switch can be made as thermostat housing (see illustrations 4.9a, b does not move at all, the fault lies in the wiring follows.
Page 103: All Models
UNREGISTERED VI Cooling system 3«5 11 Heat the coolant, stirring it gently. When the temperature reaches around 50°C the meter should read 154 ohms. When the temperature reaches around 80°C the meter should read between 47 and 53 ohms. When the temperature reaches around 100°C the meter should read between 26 and 29 ohms.
Page 104 UNREGISTERED VERSION OF PICTURED UNREGISTERED VERSION OF PICTURED 3»6 Cooling system THERMOSTAT THERMOMETER 6.6b ... and withdraw the thermostat 6.8 Thermostat testing set-up with the specifications given at the beginning of how it fits (see illustration). Discard the cover and tighten the clamps securely. Also connect O-ring as a new one must be used.
Page 105 UNREGISTERED VERSION OF PICTURE-DESK 1 ["UNREGISTERED VERSION OF PICTURE-DESK Cooling system 3*7 7.4a Radiator mounting bolts (arrowed) - 7.4b Radiator mounting bolts (arrowed) - 7.4c Radiator mounting bolts (arrowed) - 1991 to 1995 TDM models 1996-on TDM models and all TRX models XTZ models.
Page 106 3»8 Cooling system '^^^.Jjjik miMU 8.11a Fit the O-ring into the groove in the 8.11b .. then fit the cover and its two 8.12a Fit a new O-ring onto the body... cover... bolts Installation Also install the exhaust system (see Chapter 4). then slit it at each union so that it can be peeled 15 Refill the cooling system (see Chapter 1).
Page 107 Chapter 4 Fuel and exhaust systems Contents Air filter - cleaning and renewal ..........see Chapter 1 Fuel pump - check and renewal Air filter housing - removal and installation ..........4 (TRX, XTZ and 1991 to 1998 TDM models) ......... 14 Carburettor overhaul - general information ..........
Page 108 4*2 Fuel and exhaust systems Carburettors Type 1991 to 1998 TDM models, all TRX and XTZ models ....... Mikuni BDST38 1999 TDM models ..................Mikuni BDSR38 ID mark 1991 to 1995 TDM models ................ 3VD 00 1996 to 1998 TDM models ................ 4TX 00 1999 TDM models ..................
Page 109: Fuel Tank Removal And Installation
Fuel and exhaust systems 4*3 any fuel on your skin, rinse it off immediately 1 General Information and with soap and water. When you perform any precautions kind of work on the fuel system, wear safety glasses and have a fire extinguisher suitable for a class B type fire (flammable liquids) on hand.
Page 110 4»4 Fuel and exhaust systems 2.9b ... and the breather hose (arrowed) 2.9a Detach the fuel hose (A), the vacuum 2.10a Remove the rear mounting bolt hose (B)... (arrowed)... models, carefully lift the tank off the frame and the breather hose to its union and detach the 18 Inspect the tank mounting rubbers for remove it, bringing the remote fuel tap and hoses hose (see illustration).
Page 111 Fuel and exhaust systems 4*5 2.27a Fuel outlet screws (arrowed) - 1991 to 1995 TDM models 2.26 Note which hose fits where before detaching them screws a little first, then tighten them evenly a 29 On TRX models, the fuel tap is automatic, large enough for storing the petrol.
Page 112: Fuel Tank
5 Installation is the reverse of removal. Check adjust the idle fuel/air mixture and be sure the to a Yamaha dealer equipped with an exhaust the condition of the various hoses and their machine...
Page 113 Fuel and exhaust systems 4»7 6 Carburettor overhaul - general information 1 Poor engine performance, hesitation, hard starting, stalling, flooding and backfiring are all signs that major carburettor maintenance may be required. 2 Keep in mind that many so-called carburettor problems are really not carburettor problems at all, but mechanical problems within the engine or ignition system malfunctions.
Page 114 4*8 Fuel and exhaust systems 7.7b 7.7a Slacken the upper or lower clamp screws as required . and remove the carburettors (arrows)... 9 If necessary, slacken the clamps securing clamp the two warmer system coolant hoses to disassembly, Hs> prevent loss of coolant and disconnect the hose the intake rubbers and remove them, noting from the side of each carburettor.
Page 115 Fuel and exhaust systems 4*9 8.4 Lift out the diaphragm/piston assembly 8.3 Remove the air passage O-ring with the washer (see illustration). If the E-clip is needle valve from the tab on the float, noting bottom of the spring (see illustrations 10.12b removed from the needle, note which notch it is how it fits (see illustration).
Page 116: Ignition System
5»1 Chapter 5 Ignition system Contents General information .................. Neutral switch - check and replacement ........ see Chapter 9 Ignitor unit - check, removal and installation .......... Pick-up coil - check and replacement ............. 4 Ignition (main) switch - check, removal and Sidestand switch - check and replacement ......
Page 117 5*2 Ignition system existent, further investigation will be necessary. 2 Ignition system - check Before proceeding further, turn the ignition OFF. 4 The ignition system must be able to produce a spark which is capable of jumping a particular size gap. A healthy system should produce a spark capable of jumping at least 6 mm.
Page 118 Loose, corroded or damaged wiring Yamaha dealer equipped with diagnostic testing and the engine running at high speed. connections, broken or shorted wiring equipment.
Page 119 Replacement by a Yamaha dealer. If the coil is confirmed to be 6 The pick-up coil is wired integrally with the faulty, it must be renewed; the coil is a sealed...
Page 120 Take the machine to check is complete, install the timing inspection 4 Unscrew the timing inspection plug from the a Yamaha dealer for testing. plug using a new O-ring and tighten it securely. alternator cover (see illustration). Discard the cover O-ring as a new one must be used.
Page 121 6 If the sensor is suspected of being faulty, disconnect the throttle sensor's wire connector. switch OFF. take it to a Yamaha dealer for further testing. If Using a multimeter set on the K-ohms range, it is confirmed to be faulty, it must be...
Page 122 Chapter 6 Frame, suspension and final drive Contents Drive chain - removal, cleaning and installation ........15 Sprockets - check and replacement ............16 Drive chain and sprockets - check, adjustment Sidestand - check ..............see Chapter 1 and lubrication ..............see Chapter 1 Sidestand - lubrication ............see Chapter 1 Footrests, brake pedal and gearchange lever - Sidestand - removal and installation ............
Page 123 6*2 Frame, suspension and final drive Rear suspension Shock absorber spring free length TDM models Main spring ................... 144 mm Sub spring ..................... 69 mm TRX models ....................220.5 mm XTZ models ....................240 mm Swingarm - XTZ models Side clearance ..................0.4 to 0.7 mm Bearing spacer length (right-hand) ............
Page 124 UNREGISTERED VI UNREGISTERED VERSION OF PICTURED Frame, suspension and final drive 6»3 3.1a Note how the spring end (arrowed) locates 3.1b Footrest bracket bolts (A), footrest rubber screws (B) for signs of cracking or splitting at the welded two bolts securing the bracket and remove it 1 General information joints.
Page 125: Brake Pedal
6*4 Frame, suspension and final drive 3.6 Unscrew the nut (A) and withdraw the 3.7 Remove the split pin (arrowed) and 3.9a Remove the pinch bolt (A) and slide bolt (B) withdraw the pivot pin the pedal off the shaft. Note the alignment of the punch mark (B) with the notch (C) renewed by removing the two screws that secure Brake pedal...
Page 126 Frame, suspension and final drive 6*5 3.14c 3.14a Slacken the locknuts (arrowed) and 3.14b Unscrew the pivot bolt. . and remove the lever, noting the washers thread the rod out of the lever and arm lever and the arm (the rod is reverse-threaded on one end and so will simultaneously unscrew from both lever and arm when turned in the one direction) (see illustration).
Page 127 6*6 Frame, suspension and final drive 5.3 Clutch switch wiring connector 5.5a On TDM models, remove the blanking 5.5b Handlebar clamp bolts (arrowed) - (arrowed) - TDM models caps TDM models and leave the holder in place, remove the to detach the cables from the carburettors. surfaces of the holder (see illustration).
Page 128: Front Brake Lever
Frame, suspension and final drive 6*7 5.9 Handguard retaining screw - 5.8d Ensure that the flat (A) aligns with the cut-out (B) XTZ models aligns correctly with the corresponding cut- 11 Installation is the reverse of removal. out in the holder (see illustration). Tighten Apply grease to the pivot bolt shaft, or on TRX the retaining bolts, positioning bolts and models to the collar, and the contact areas...
Page 129 UNREGISTERED VI 6*8 Frame, suspension and final drive 6.3 Brake hose clamp bolt (arrowed) 6.4 Handlebar holder clamp bolt (A), fork 6.5 Slacken the fork clamp bolt (A), and If clamp bolt (B), fork top bolt (C) required the fork top bolt (B) 3 Unscrew the brake hose clamp bolt from each (see illustration).
Page 130 Frame, suspension and final drive 6»9 7 Forks - disassembly, Top bolt inspection and reassembly 1991 to 199S TDM models Disassembly 1 Always dismantle the fork legs separately to avoid interchanging parts and thus causing an accelerated rate of wear. Store components in separate, clearly marked containers (see illustration).
Page 131 V-blocks and a dial gauge, or have it done illustration). by a dealer (see illustration). Yamaha do not 12 To separate the tube from the slider it is specify a runout limit, but if the tube is bent it necessary to displace the top bush and oil seal.
Page 132 (see illustration). Press the bush squarely into its recess in the slider as far as possible, then install the oil seal washer with its flat side facing up (see illustration). Either use the Yamaha service tool or a 7.22a Install the top bush ...
Page 133 6»12 Frame, suspension and final drive 7.27a Insert the damping adjuster rod 7.26a Pour the oil into the top of the tube 7.26b Measure the oil level with the fork held vertical if it wasn't removed) onto the damper rod as far as it will go, then counter-hold it and tighten the locknut securely against it (see illustration and 7.5).
Page 134 45 Check the fork tube for runout (bending) using seat. Take care not to do this forcibly or the seat dismantling the fork, use the Yamaha service tool V-blocks and a dial gauge, or have it done by a may be damaged. Then pull the tube sharply (TDM models - pt.
Page 135 Invert the fork leg over a suitable container on the spring. Screw the top bolt carefully into the 7.22b). Either use the Yamaha service tool or a and pump the fork vigorously to expel as much fork tube making sure it is not cross-threaded.
Page 136 UNREGISTERED VI VERSION OF PICTURE-D Frame, suspension and final drive 6*15 7.59 Front fork components - XTZ models 1 Top bolt 7 Damper rod and rebound spring 13 Top bush 2 O-ring 8 Damper rod seat 14 Slider 3 Spacer 9 Dust seal 15 Oil drain screw and sealing washer - 4 Spring seat...
Page 137: Steering Stem
Repeat this operation until the top bush the specified torque setting at this stage if the tube 7.22b). Either use the Yamaha service tool or a and seal are tapped out of the slider (see is held between the padded jaws of a vice, but do suitable piece of tubing to tap the bush fully into illustration 7.12).
Page 138 UNREGISTERED VERSION 0 UNREGISTERED VI Frame, suspension and final drive 6*17 8.3 Disconnect the horn wiring connectors, then unscrew the 8.4a Free the cable and wiring from the guides (arrowed) on the top bolts (arrowed) and displace the brake hose/horn assembly yoke ...
Page 139: Steering Head Bearings
Alternatively, have the races installed by a Yamaha dealer equipped with the bearing race installing tools. |tflflfgg| Installation of new bearing UWilifii outer races is made much...
Page 140: Rear Shock Absorber
(see illustration). grinder. Take the steering stem to a Yamaha 6 Remove the seat (see Chapter 8). If required Support the shock absorber and withdraw the dealer if required. Check the condition of the dust for improved clearance, also remove the exhaust...
Page 141 6*20 Frame, suspension and final drive 10.7a Linkage rod to linkage arm bolt (A), shock absorber lower 10.7b Linkage rod to linkage arm bolt (A), shock absorber lower mounting bolt (B) - TRX models mounting bolt (B) - XTZ models securing the linkage rods to the linkage arm (see the upper mounting bolt, then manoeuvre the Installation...
Page 142 Frame, suspension and final drive 6»21 3 Unscrew the nuts and withdraw the bolts securing the shock absorber and the linkage rods to the linkage arm (see illustrations). Note which bolts fit where. 4 Unscrew the nut and withdraw the bolt securing the linkage rods to the swingarm and remove the rods.
Page 143: Front Forks
6*22 Frame, suspension and final drive 14 Lubricate the needle roller bearings and the spacers with molybdenum disulphide grease (TRX models) or lithium-based grease (XTZ models) and install the inner sleeves. 15 Check the condition of the grease seals and renew them if they are damaged or deteriorated.
Page 144 UNREGISTERED VERSION OF PICTURE-DESK 6*24 Frame, suspension and final drive r ------- h 12.9 Compression damping adjuster-TRX 12.10a Slacken the locknut (A) and turn the models adjuster (B) as required ... the shock absorber reservoir {see illustration). 13 Swingarm- §^ Turn the adjuster clockwise to increase damping and anti-clockwise to decrease it.
Page 145 rUHREGISTERED VERSION OF PICTURE-DESK i, suspension and final drive 6*25 13.10 Withdraw the pivot bolt and remove 13.9b ... then unscrew the swingarm nut 13.9a Remove the blanking caps if the swingarm - TDM shown fitted ... (arrowed) - TDM shown the bearing spacer(s) (see illustrations).
Page 146 20 On XTZ models, feed the brake hose all old grease off the spacers, the two needle gauge. Yamaha do not specify a maximum roller bearings and the two plain bushes in the through its guide on the inside of the swingarm runout limit but if it is obviously bent it must be and install it onto the caliper (see Chapter 7);...
Page 147 Done this way, original equipment and supplied as a spare part you will be able to install any shims required from Yamaha dealers is of the endless type. as the swingarm is refitted. You will need a Warning: NEVER install a drive vernier gauge to do this accurately.
Page 148 5 Soak the chain in paraffin (kerosene) for the cover (see illustration 15.2c). approximately five or six minutes. Caution: Don't fitted by a Yamaha dealer. 2 On TRX models, unscrew the gearchange use gasoline (petrol), solvent or other 12 Remove the engine sprocket cover as lever linkage arm pinchbolt and remove the arm cleaning fluids.
Page 149 UNREGISTERED VI UNREGISTERED VERSION OF PICTURED Frame, suspension and final drive 6*29 16.7 Bend back the lockwasher tab(s) 16.10a Fit a new lockwasher. 16.8 Slide the sprocket off the shaft and (arrowed), then unscrew the nut remove it 16.10d Bend the tabs up against the nut 16.10b ...
Page 150 6*30 Frame, suspension and final drive 17.2 Lift the sprocket coupling out of the 17.3 ... and remove the rubber dampers 17.5 Fit the spacer into the bearing if it wheel... was removed general deterioration (see illustration). Renew 2 Lift the sprocket coupling out of the wheel 17 Rear sprocket the rubber dampers as a set if necessary.
Page 151 7»1 Chapter 7 Brakes, wheels and tyres Contents Brake calipers - removal, overhaul and installation ......... 3 General information ................. 1 Brake discs - inspection, removal and installation ........4 Rear brake master cylinder - removal, overhaul and installation ... 6 Brake fluid level check ........
Page 152 UNREGISTERED VI UNREGISTERED VERSION OF PICTURED 7»2 Brakes, wheels and tyres Wheels Wheel runout (max) Axial (side-to-side) TDM and XTZ models ................0.5 mm TRX models ................... 2.0 mm Radial (out-of-round) TDM and XTZ models ................1.0 mm TRX models ................... 2.0 mm Tyres Tyre pressures .....................
Page 153 Brakes, wheels and tyres 7»3 2.1a Remove the pad cover... 2.1b ... then remove the retaining clips . 2.1c ... and withdraw the pad pins 2.1 d Remove the pad spring ... 2.1 e ... and lift out the pads your health.
Page 154 Yamaha as leverage. Due to the increased friction outer pad, noting how it sits in the caliper bracket pads.
Page 155 Brakes, wheels and tyres 7*5 A fcji| A Apply Duckhams Copper 10 or equivalent to the shaded areas B Apply Shin- Etsu G-40M or equivalent silicone grease to the shaded areas 2.9b Special lubricants are required in the 2.9c Apply the recommended lubricants to (and the pad friction areas inside the caliper recommended anywhere salt is used on the roads) to prevent...
Page 156 7*6 Brakes, wheels and tyres 2.11c Slide the caliper onto the disc . 2.11d .. and tighten the mounting 2.11e ... and the pad pins to the specified bolts ... torque then fit the inner pad, locating the cutout against 13 Operate the brake lever several times to bring caliper shield and remove the shield (see the guide (see illustration 2.2d).
Page 157 U.Hi.lS.iHiD.iHSin.nFPICUHi-DiSK Brakes, wheels and tyres 7*7 slide the caliper off the disc (see illustrations). bores using a piece of wood and displace the Caution: Do not, under any circumstances, 4 If the calipers are being overhauled, remove opposite side first, then remove the seals (see use a petroleum-based solvent to clean brake the brake pads (see Section 2).
Page 158: Front Brake Master Cylinder
7»8 Brakes, wheels and tyres 4.2 Set up a dial gauge with the probe 4.3 Using a micrometer to measure disc 4.5 Unscrew the bolts (arrowed) and contacting the brake disc, then rotate the thickness remove the disc - TDM rear disc shown wheel to check for runout illustration).
Page 159 U.Hi.lS.iHiD.iHSin.nFPICUHi-DiSK Brakes, wheels and tyres 7*9 5.4b Brake switch wiring connectors 5.6a Brake hose banjo bolt (arrowed) - 5.4a Brake switch wiring connector (arrowed) - TDM models (arrowed) - TRX models TDM models 5.7b ... and hose clamp - TRX models 5.6b Brake hose banjo bolt (arrowed) - 5.7a Reservoir mounting bolt...
Page 160: Rear Brake Master Cylinder
D.iHSin.nFPICUHi-DJSin 7*10 Brakes, wheels and tyres 5.13b Lay out the internal parts as shown, 5.24 Align the clamp mating surfaces with 5.13a ... then depress the piston and even if new parts are being used, to avoid remove the circlip using a pair of internal the punch mark on the handlebar confusion on reassembly circlip pliers...
Page 161 Brakes, wheels and tyres 7*11 teser voir hose clamp (A), 6.4b Master cylinder reservoir screw 6.4c Master cylinder reservoir boa (arrowed) - TRX models (arrowed) - XTZ models brake banjo bolt (B) - TDM models ■rn '••■''.. ,jj, , .4 ,.
Page 162 7«12 Brakes, wheels and tyres brake fluid (see Daily (pre-ridej checks) and 15 Install the spring in the master cylinder so bleed the system following the procedure in that its tapered end faces the piston. Section 8. 16 Lubricate the piston, seal and cup with clean 26 On TDM models, install the seat, and on XTZ brake fluid.
Page 163 Brakes, wheels and tyres 7*13 8.6a Brake caliper bleed valve 8.6b To bleed the brakes, you need a spanner, a short section of clear tubing, and a clear container half-filled with brake fluid 6 Flush the old brake fluid from the system, refill submerge the other end in the brake fluid in the BWJjrPI If it's not possible to with new DOT 4 brake fluid (see Da//y (pre-ride)
Page 164 7»14 Brakes, wheels and tyres Fix atrtng here ___ L 4 If a string is used, have your assistant hold String hew taut one end of it about halfway between the floor and the rear axle, touching the rear sidewall of the Check for contact here tyre.
Page 165 Brakes, wheels and tyres 7«15 11.4 Slacken the clamp bolt (A) and unscrew the axle (B) 11.5 Speedometer cable (A), disc cover screws (B), split pin (C), axle nut (D) the tabs locate in the slots (see illustrations On 1999 TDM models, trace the wiring from the 8 Check the axle for straightness by rolling it on 11.7a and b).
Page 166 UNREGISTERED VERSION OF PICTURE-DESK 7*16 Brakes, wheels and tyres Now tighten the axle clamp bolt on the bottom of 5 Disengage the chain from the sprocket and 12 Rear wheel - the right-hand fork to 'he specified torque setting remove the wheel from the swingarm (see (see illustration 11.4).
Page 167 Brakes, wheels and tyres 7»17 12.10 Manoeuvre the wheel into position 12.11 On TRX models, make sure the axle 12.12 Where fitted, use a new split pin and fit the chain onto the sprocket head locates correctly in the adjustment marker the brake caliper bracket, on XTZ models everything is correctly aligned, then fit the left-...
Page 168 7*18 Brakes, wheels and tyres 13.10 A socket can be used to drive in the 13.12a Fit the drive plate as described . 13.12b ... then fit the retainer plate bearing 6 Lay the wheel on its other side so that the contact the outer race of the bearing, drive it in rim of the hub (see illustration).
Page 169 Brakes, wheels and tyres 7*19 13.26b ... noting how it fits 13.23 Where the seal sits flush with the 13.26a Use a socket to drive out the rim, a piece of wood can be used as spacer... 13.27 Drive the bearing out from the inside shown 13.26c Lever out the grease seal using acetone or brake system cleaner.
Page 170 Yamaha dealer or tyre fitting. 5 Note that punctured tubeless tyres tyre fitting specialist (see illustration). can in...
Page 171 Chapter 8 Bodywork Contents Engine bashplate - removal and installation ........7 General information ..............1 Fairing - removal and installation ..........5 Seat - removal and installation ............2 Fairing side panels - removal and installation ......... 4 Side covers - removal and installation ........... 3 Front mudguard - removal and installation ........
Page 172 8*2 Bodywork 2.3 Make sure the seat locates correctly against the tank ■ 2.2 Turn the key to release the latch peg- type (arrowed) located behind the rider's seat, and turn it hooks, then push down on the rear of the seat to 2 Seat- clockwise to unlock the seat.
Page 173 UNREGISTERED VI UNREGISTERED VI Bodywork 8«3 3.1 Disconnect the tail light wiring connector (arrowed) L ^ ^ -^^^Htf?" SS^Bj^*^gy 2.11 Locate the tab (A) under the bracket (B) 11 Installation is the reverse of removal. the tall light wiring connector (see illustration). 5 Remove the six screws securing the side Make sure the tab at the front of the seat 2 Unscrew the four bolts securing the side...
Page 174 Scaned by Stalker UNREGISTERED VI UNREGISTERED VI...
Page 175 8*4 Bodywork 3.7b ... then draw the cover away to 4.1 a Remove the four screws 4.1b ... and remove the panel release the pegs from the grommets (arrowed)... (arrowed) 2 Installation is the reverse of removal. panel, noting how it locates onto the lug on liring side panels the frame.
Page 176 Bodywork 8*5 5.2b ... then draw the fairing forward and remove the auxiliary light 5.2a Remove the screws and bolts (arrowed)... bulbholder... 5 Fainng - removal and installation 1991 to 1995 TDM models Removal 1 Remove the fairing side panels (see Section 4). 2 Remove the two screws and two bolts securing the fairing (see illustration) on each side.
Page 177 8*6 Bodywork 5.10a Unscrew the nuts (arrowed). 5.10b ... withdraw the screws and 5.10c ... and the rubber pad remove the mirrors... 5.11a Disconnect the headlight wiring 5.11b ... the auxiliary light wiring 5.11c .. and the turn signal wiring connector (arrowed)...
Page 178 UNREGISTERED VI Bodywork 8*7 ^m ■ •Mr 6.2a On TDM models, note how the 5.15 Disconnect the headlight wiring 5.16 The headlight comes away with the fairing connector (A) and the auxiliary light wiring mounting brackets fit connector (B) for each light Make sure the wiring connectors are correctly the XTZ models cable and draw it up through the guide on...
Page 179: Electrical System
UNREGISTERED VI Chapter 9 Electrical system Contents Alternator rotor and stator - removal, inspection and installation . . 32 Horn - check and replacement ..............26 Battery - charging ..................4 Ignition (main) switch - check, removal and installation ......18 Battery - removal, installation, inspection and maintenance ....
Page 180: Starter Motor
UNREGISTERED VI UNREGISTERED VF " 9*2 Electrical system Starter motor Brush length Standard ....................12.5 mm Service limit (min) ..................5 mm Commutator diameter Standard ....................28 mm Service limit (min) ..................27 mm Mica depth ....................0.7 mm Armature coil resistance ................0.01 ohms @ 20°C Fuses 1991 to 1995 TDM models...
Page 181: Removal And Installation
UNREGISTERED VERSION OF PICTURED UNREGISTERED VERSION 0 Electrical system 9*3 Torque settings Transmission output shaft retainer plate bolts ..........10Nm Starter motor mounting bolts ................. 10 Nm Alternator rotor screws ................... 7 Nm Pick-up coil screws ..................4 Nm Alternator rotor bolt ..................130 Nm be narrowed down by noting if other components 3 Battery-removal, installation, |^...
Page 182: Inspection And Maintenance
2 If the battery is fully discharged, Yamaha 12 If the motorcycle sits unused for long periods and lift out the box (see illustrations). 5 On...
Page 183: Tail Light
Electrical system y»j> 5.1a Fusebox - TDM models 5.1 b Fusebox - TRX models 5.1c Cooling fan fuse - XTZ models 4 Install the battery (see Section 3). fuse is clearly marked with its rating and must signals and instrument cluster lights. If none of 5 If the motorcycle sits unused for long periods only be replaced by a fuse of the correct rating.
Page 184: Brake Light
9*6 Electrical system should be wiped carefully when cold with a rag soaked in methylated spirit and dried before fitting. Warning: Allow the bulb time to cool before removing it if the headlight has just been on. Headlight 1 For best access to the headlight bulb(s), remove the fairing on TDM models and the relevant fairing side panel on XTZ models (see Chapter 8).
Page 185 Electrical system'"w 7.8 Pull the bulbholder out of the base of 8.2a Removing the headlight - 8.2b Removing the headlight - the headlight TRX models XTZ models clockwise to release it from the holder (see illustration). Install bulb bulbholder, then install the bulbholder in the headlight.
Page 186 9*8 Electrical system always check the battery voltage first. Low battery voltage indicates either a faulty battery or a defective charging system. Refer to Section 3 for battery checks and Sections 30 and 31 for charging system tests. Also, check the fuse (except XTZ models) (see Section 5) and the switch (see Section 19).
Page 187 12.1c Turn signal lens screw (arrowed) - 12.1a Turn signal lens screw (arrowed) - 12.1b Turn signal lens screw (arrowed) - XTZ models TRX models TDM models 12 Turn signal bulbs - renewal §$> 1 Remove the screw securing the turn signal lens and remove the lens, noting how it fits (see illustrations).
Page 188 9*10 Electrical system 13.2a Front turn signal mounting nut 13.2b Rear turn signal mounting nut 13.1f Rear turn signal wiring connectors - (arrowed) - TDM models (arrowed) - XTZ models XTZ models 2 On TDM and XTZ models, pull back the rubber boot and unscrew the nut securing the turn signal (see illustration).
Page 189: Instrument Cluster
Electrical system 9«11 14.9a Rear brake light switch (arrowed) - 14.9b Rear brake light switch (arrowed) - 14.9c Rear brake switch wiring connector (arrowed) - TDM models TDM models TRX models release the clips on the instrument cluster Rear brake pedal switch turn the adjusting ring on the switch body until the brake light is activated when required.
Page 190 If it is believed that it is only available as part of the guides, and remove it from the bike, noting its to be faulty, take the motorcycle to a Yamaha speedometer and tachometer assembly. correct routing.
Page 191 (see illustration). Yamaha dealer for assessment. Replacement wire is for the left-hand terminal, the black for the 6 On TRX, XTZ and 1991 to 1998 TDM models,...
Page 192 9»14 Electrical system poor wire connection or break in any of the circuit wiring. Check that the fuel level warning light bulb has not blown. Replacement 5 Refer to Section 16 for renewal of the fuel gauge and warning light bulb. 6 To access the sender unit, first remove the fuel tank as described in Chapter 4 and drain ail fuel from the tank into a suitable container.
Page 193 Electrical system 9*15 switch on - continuity) - see the wiring diagrams at the end of this Chapter. 5 If the continuity check indicates a problem exists, refer to Section 20, remove the switch and spray the switch contacts with electrical contact cleaner.
Page 194 9*16 Electrical system 21.2a Neutral switch wiring connector (A), 21.2b Neutral switch wiring connector (A), 21.2c Neutral switch wiring connector sidestand switch wiring connector (B) - sidestand switch wiring connector (B) - (arrowed) - XTZ models TDM models TRX models the connector (see illustrations).
Page 195 O.RE.ISEERiP VERSION Of RICEORiTiiiSr Electrical system 9»17 22 Sidestand switch - check and replacement Check 1 The sidestand switch is mounted on the sidestand. The switch is part of the safety cutout circuit which only allows the starter motor to operate if the transmission is in neutral or the clutch lever is pulled in and the sidestand is up.
Page 196 9*18 Electrical system and fuel tank for access (see Chapters 8 and the transmission is in gear unless the frame in the area where the fuel tank and side 4). The diode is part of the safety circuit which sidestand is up and the clutch lever is pulled cover meet.
Page 197 UNREGISTERED VI Electrical system 9»19 Replacement 5 The starter cut-off relay is located under the seat on all except 1996-on TDM models, where it is behind the fairing. Remove the seat or fairing for access (see Chapter 8). Disconnect the relay wiring connector and remove the relay (see Illustrations 25.2a and b, and 11.3b).
Page 198 9*20 Electrical system 27.7 Pull back the covers to access the terminal nuts 28.4a Unscrew the bolts (arrowed). motor and discard it as a new one must be used. detach the leads (see illustration). Remove the 28 Starter motor - relay with its rubber sleeve from its mounting lug Installation on the frame.
Page 199 Electrical system 9»21 29.1 Unscrew the terminal nut and detach the lead 29.2 Note the alignment marks (arrowed), or make your own 29.3 Unscrew the long bolts (arrowed) 29.4a Remove the front cover... 29.4b ... and slide off the shims main housing and the front and rear covers, or Remove the shims from the front end of the 29 Starter motor - disassembly, §^...
Page 200 9*22 Electrical system 29.6 Withdraw the armature 29.7 Unscrew the terminal nut (A) and remove the washers, then lift out the brushplate (B) 6 Withdraw the armature from the main terminal bolt from the main housing. Remove the commutator and compare It to the housing (see illustration).
Page 201 UNREGISTERED VI Electrical system U»ZJ 29.15a Fit the brushplate seat 29.15b Make sure the insulators are in place.. 15c ... then install the terminal bolt assembly into the housing and 29.15d . and fit the washers and nut brushplate seat... If the shaft is damaged or worn, renew the 17 Fit each brush into its holder and press it back without becoming entangled with the exposed...
Page 202 23 Install the starter motor (see Section 28). checking the charging system should be left to a to the disconnected negative (-ve) lead (see Yamaha dealer. 29.20b ... and fit the tabbed washer into the cover 29.21 Install and tighten the long bolts...
Page 203 Electrical sysiefrFf^zf 31.3 Checking the charging system leakage rate 32.2a Alternator wiring connector (A), pickup 32.2b Alternator wiring connector (A), pickup - connect the ammeter as shown coil wiring connector (B) - TDM models coil wiring connector (B) - TRX models illustration).
Page 204 (see illustration). 11 To remove the rotor from the shaft it is necessary to use a rotor puller. Yamaha provide a special tool (Pt. Nos. 90890-01362 and 90890- 01382, or alternatively a similar tool can be set up as shown, using the threaded holes in the rotor (see illustration).
Page 205 UNREGISTERED VI Electrical system 9*27 32.12a Remove the rotor screws (A). 32.12b ... and the pick-up coil screws (B), 32.14a If removed, fit the Woodruff key and free the wiring grommets (C) into its slot... then remove the assembly, noting how the rubber wiring grommets fit (see illustrations).
Page 206 33 Regulator/rectifier- §| check and replacement Check 1 Yamaha provide no test specifications for the regulator/rectifier. If it is suspected of being faulty, first check all other components and wiring in the charging circuit, referring to the relevant Sections in this Chapter and to the wiring diagrams at the end.
Page 207 Wiring diagrams 9*29 *6o Cxj—]»^fi I ^ JICM _____ Scaned by Stalker...
Page 208 | UNREGISTERED VERSION 01 UNREGISTERED VI 9»30 Wiring diagrams Scaned by Stalker | ONREGISTERED VERSION 0 ONREGISTEREDVI...
Page 209 I UNREGISTERED VI Wiring diagrams 9»31 ____ Scaned by Stalker | UNREGISTERED VERSION OF PICTURE-DESK...
Page 210 9»32 Wiring diagrams Scaned by Stalker...
Page 211 gauge Starter circuit Neutral Starter cut-off relay switch rnotor XTZ750...

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